Failed engine now out of car and on trolley with good IRD removed ready to fit to replacement engine and then pop the whole lot back in the car.

Found a broken gearbox connector, 1st or reverse switch so fitted a spare plug to the loom.

So the only ancillaries I left in the vehicle that is being repaired are the power steering pump which I removed and placed on the inner wing. This saved draining fluid. Also the air con compressor which I removed and tied out of the way in front of the bottom valance. This saved de gassing the system.

Replacement engine with working IRD now in car. Just have to connect it all up and rebuild the front subframe and wishbones, driveshafts etc. If I did it again I would remove the bolts holding the manual gear lever link arms on the bulkhead. These fit to the rods with the press fit ball ends. With the link arms still fitted there is a tendency for the link arms to catch on the coolant hose at rear centre of engine. Some mm precision trolley moving required !! The alternator prevents moving it forward too much.

Took some photos in the engine bay while engine was removed. Not normally seen and may be useful in the future to locate component fixings etc. Will post shortly.

Here you go - engine bay shots, the bits that you can't easily see with the engine in place. Photos taken standing inside the engine bay with some key components listed to allow you to work out where you are looking ! TD4 Manual Facelift vehicle.


Looking up at LH end of steering rack, top is the fuel cut off button, facelift car so fuel pressure sensor seen at bottom in the fuel line run. Steering rack rod goes out through inner wing.


Same corner moving around to show air con connectors.

Interior heater matrix pipes going into car.

RHS of steering rack (where the RHD column fits to rack) brake servo and power steering pipes.

RH side engine mount (TD4) ABS unit (modulator and pump), screen wash filler pipe and a loose temporary power steering pump sitting awaiting refitting to new engine.

Moving around to show the intercooler and fan, also horn.

LHS of intercooler, air con pressure sensor, another horn.


Rear of engine and gearbox (with IRD) before fitting. Exhaust manifold and pipe bottom left, turbo on right and intercooler pipe.


Gearbox end before fitting.


Front of engine (chain attached for support when fitting - purely to support and provide small amount of lift and tilt, major alignment done with trolley and packing blocks under engine and gearbox. Safety really !


Serpentine belt end of engine, obviously no belt and power steering pump and air compressor not yet fitted. Thermostat next to top left pulley. Much easier to change with engine on the floor ! Alternator at right hand end of photo.

If anyone has a question about any component or what they are - fire away !!

andyfreelandy said:

Here you go - engine bay shots, the bits that you can't easily see with the engine in place. Photos taken standing inside the engine bay with some key components listed to allow you to work out where you are looking ! TD4 Manual Facelift vehicle.

View attachment 342109
Looking up at LH end of steering rack, top is the fuel cut off button, facelift car so fuel pressure sensor seen at bottom in the fuel line run. Steering rack rod goes out through inner wing.

View attachment 342110
Same corner moving around to show air con connectors.
View attachment 342111
Interior heater matrix pipes going into car.
View attachment 342112
RHS of steering rack (where the RHD column fits to rack) brake servo and power steering pipes.
View attachment 342113
RH side engine mount (TD4) ABS unit (modulator and pump), screen wash filler pipe and a loose temporary power steering pump sitting awaiting refitting to new engine.
View attachment 342114
Moving around to show the intercooler and fan, also horn.
View attachment 342115
LHS of intercooler, air con pressure sensor, another horn.

View attachment 342116
Rear of engine and gearbox (with IRD) before fitting. Exhaust manifold and pipe bottom left, turbo on right and intercooler pipe.

View attachment 342117
Gearbox end before fitting.

View attachment 342118
Front of engine (chain attached for support when fitting - purely to support and provide small amount of lift and tilt, major alignment done with trolley and packing blocks under engine and gearbox. Safety really !

View attachment 342119
Serpentine belt end of engine, obviously no belt and power steering pump and air compressor not yet fitted. Thermostat next to top left pulley. Much easier to change with engine on the floor ! Alternator at right hand end of photo.

If anyone has a question about any component or what they are - fire away !!

Click to expand...

This is invaluable info!
Well done for documenting it…

Anyone recognise the vehicle in the 'gearbox end' photo ??

andyfreelandy said:

Anyone recognise the vehicle in the 'gearbox end' photo ??

Click to expand...

1965 Cortina GT?
(Just guessing from your sig!)

@andyfreelandy thanks for the pics! Question please; which gearbox switch is that highlighted in my grab of your picture ? First or reverse? Thanks in advance.

Reverse.

And so I know too now where 1st is... I may have a problem with that switch not allowing HDC to engage forwards.

andyfreelandy said:

Anyone recognise the vehicle in the 'gearbox end' photo ??

Click to expand...

Yep, yes, me Sir!

Freddie17 said:

1965 Cortina GT?
(Just guessing from your sig!)

Click to expand...

It's a beaut.

andyfreelandy said:

Here you go - engine bay shots, the bits that you can't easily see with the engine in place. Photos taken standing inside the engine bay with some key components listed to allow you to work out where you are looking ! TD4 Manual Facelift vehicle.

View attachment 342109
Looking up at LH end of steering rack, top is the fuel cut off button, facelift car so fuel pressure sensor seen at bottom in the fuel line run. Steering rack rod goes out through inner wing.

View attachment 342110
Same corner moving around to show air con connectors.
View attachment 342111
Interior heater matrix pipes going into car.
View attachment 342112
RHS of steering rack (where the RHD column fits to rack) brake servo and power steering pipes.
View attachment 342113
RH side engine mount (TD4) ABS unit (modulator and pump), screen wash filler pipe and a loose temporary power steering pump sitting awaiting refitting to new engine.
View attachment 342114
Moving around to show the intercooler and fan, also horn.
View attachment 342115
LHS of intercooler, air con pressure sensor, another horn.

View attachment 342116
Rear of engine and gearbox (with IRD) before fitting. Exhaust manifold and pipe bottom left, turbo on right and intercooler pipe.

View attachment 342117
Gearbox end before fitting.

View attachment 342118
Front of engine (chain attached for support when fitting - purely to support and provide small amount of lift and tilt, major alignment done with trolley and packing blocks under engine and gearbox. Safety really !

View attachment 342119
Serpentine belt end of engine, obviously no belt and power steering pump and air compressor not yet fitted. Thermostat next to top left pulley. Much easier to change with engine on the floor ! Alternator at right hand end of photo.

If anyone has a question about any component or what they are - fire away !!

Click to expand...

Great post this is. Some very useful pics there Andy

Driveshafts and subframe back on. Wishbones cleaned and painted with Poly boots on ball joints.

IRD and Gearbox filled with oil. A good tip, easier to fill gearbox before fitting subframe if you have it removed for any reason.

Anti roll bar repaired with collars to replace the rusted rings that stop it sliding sideways.

This is going to be a nice motor !! Needs a headliner and a cream velour driver's seat and it would be mint. Anyone got a seat ??

Should finish the top end connecting up tomorrow then see what happens